Controllers and methods for bulk explosive loading systems

ABSTRACT

Controllers and methods of bulk explosive loading systems are disclosed. A controller of a bulk explosive loading system includes a communication interface configured to communicate with a human-machine interface (HMI). The HMI is configured to execute a software program configured to enable the HMI to receive user inputs from a user. The controller also includes control outputs to output control signals to electrically controllable components. The controller further includes sensor inputs configured to receive sensor signals from sensors configured to monitor the bulk explosive loading system. The controller also includes a processor configured to process recipe information received from the HMI, generate the control signals based on the recipe information to control the electrically controllable components to blend the mixture, process the sensor signals received during blending of the mixture, and transmit blending information to the HMI device. The blending information includes information regarding the blending of the mixture.

RELATED APPLICATIONS

This application is a Continuation of U.S. patent application Ser. No.16/601,176 filed on Oct. 14, 2019, and titled “CONTROLLERS AND METHODSFOR BULK EXPLOSIVE LOADING SYSTEMS,” which claims the benefit of U.S.Provisional Application No. 62/745,801 filed Oct. 15, 2018, and titled“CONTROLLERS AND METHODS FOR BULK EXPLOSIVE LOADING SYSTEMS,” both ofwhich are hereby incorporated by reference in their entireties.

BACKGROUND

Bulk explosive loading systems sometimes include on-site equipment(e.g., bulk explosive loading systems integrated into trucks) forblending and delivering explosive mixtures. These mixtures may be usedin mining and drilling. The explosive nature of these mixtures requiresprecise, safe procedures for blending the mixtures.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

To easily identify the discussion of any particular element or act, themost significant digit or digits in a reference number refer to thefigure number in which that element is first introduced.

FIG. 1 is a simplified view of a bulk explosive loading system inaccordance with some embodiments.

FIG. 2 is a simplified block diagram of the bulk explosive loadingsystem of FIG. 1 .

FIG. 3 is a simplified signal flow diagram of the bulk explosive loadingsystem of FIG. 1 .

FIG. 4 is a simplified view of a graphical user interface (GUI)displayed by the electronic display of an HMI of the bulk explosiveloading system of FIG. 1 , according to some embodiments.

FIG. 5 is a simplified flowchart illustrating a method of transforming acomputer into the HMI of the bulk explosive loading system of FIG. 1 ,according to some embodiments.

FIG. 6 is a simplified block diagram of a system illustrating the methodof FIG. 5 .

DETAILED DESCRIPTION

Bulk explosive loading systems provide a safe efficient way to deliverexplosives to a target position. Some bulk explosive loading systems maybe above ground trucks that deliver explosives into a bore hole. Otherbulk explosive loading systems may be vehicles designed to travelunderground to deliver explosives into holes within a mine. While theillustrated embodiment herein references a truck, the aspects of thedisclosure described below may be applied to other vehicle types.

An operator interacts with a controller associated with the bulkexplosive loading system to provide certain parameters for theexplosives to be delivered. However, often these controllers feature auser interface that is outdated and difficult to use. Often the userinterface is tied directly to the controller making it expensive anddifficult to update or replace. Described herein are systems, devices,and methods to provide a user interface that is independent of acontroller of the bulk explosive loading system. The user interface maybe updatable and reconfigurable intendent of the controller, includemore features than the controller, and provide a more robust interfacefor an operator.

FIG. 1 is a simplified view of a bulk explosive loading system 100according to some embodiments. The bulk explosive loading system 100illustrated in FIG. 1 is a mobile bulk explosive loading system. Thebulk explosive loading system 100 includes a truck 102 including a truckcab 104 and a truck body 106. The bulk explosive loading system 100 alsoincludes a Human-Machine Interface 108 (HMI 108), which may be locatedwithin the truck cab 104. The bulk explosive loading system 100 furtherincludes a controller 110 on or in the truck body 106. The bulkexplosive loading system 100 also includes one or more electricallycontrollable components 112, one or more sensors 114, and one or moreoperator inputs 116 on or in the truck body 106. For simplicity, the oneor more electrically controllable components 112, the one or moresensors 114, and the one or more operator inputs 116 are sometimesreferred to herein as “electrically controllable components” 112,“sensors” 114, and “operator inputs” 116, respectively.

The controller 110 is configured to control and monitor blendingprocessing, which includes closed-loop control of one or moreingredients (e.g., an emulsion explosive, dry ammonium nitrate prill,ammonium nitrate and fuel oil (ANFO), etc.) and preparation of one ormore ingredients to be delivered to a bore hole or added to a mixtureand then delivered to the bore hole. The controller 110 may use theclosed-loop control for controlling various equipment, such as, forexample, hydraulic valves, controlling pneumatic process valves,controlling electronic process valves, and setting a speed of a mixer.The explosive mixture can have a variety of ingredients, including onlyone ingredient, post-mixing. For example, the explosive mixture may bean emulsion explosive prepared by the bulk explosive loading system 100.The controller 110 may control sensitizing an emulsion matrix to achievean emulsion explosive with a desired density in a bore hole. Theemulsion explosive can be delivered as a single ingredient blended withother ingredients (e.g., dry ammonium nitrate prill, ANFO (which wasalso mixed on the truck 102 from separate containers of dry ammoniumnitrate prill and fuel oil), energy-enhancing or -reducing agents,etc.). For example, the controller 110 is configured to control thevarious electrically controllable components 112 to blend and delivervarious mixtures (e.g., explosive mixtures or mixtures used inexplosives) and receive sensor data from the sensors 114 during theblending and delivery processing. For example, the electricallycontrollable components 112 may include one or more electricallycontrollable hydraulic valves (e.g., used to dispense one or moreingredients from ingredient containers into a mixing container atcontrollable rates); one or more pumps to pump the one or moreingredients into the mixing container or to deploy a mixture into a borehole; one or more auger motors configured to blend a mixture, deliverviscous ingredients to a mixing container or to deploy the mixture intoa bore hole; other electrically controllable components; or combinationsthereof. The controller 110 may be configured to transmit one or morecontrol signals to the electrically controllable components 112 andreceive one or more sensor signals from the sensors 114 during theblending processing. For example, the sensors 114 may include one ormore pressure sensors, one or more temperature sensors, one or morespeed sensors of one or more pumps, one or more speed sensors of one ormore auger motors, flow meters, level sensors, other sensors, orcombinations thereof.

The HMI 108 is configured to record information (e.g., informationgathered by the sensors 114) gathered during the blending processing,manage product recipes to be blended, other duties, or combinationsthereof. For example, the HMI 108 may be configured to receive userinputs from a user of the bulk explosive loading system 100 to create,modify, or select mixture recipes to be followed by the controller 110,as well as delivery information to enable the controller 110 to properlydeliver the mixture to a blast site (e.g., a bore hole). The HMI 108 isalso configured to send information (e.g., recipe information, deliveryinformation) to the controller 110 prior to the start of the blendingprocess. Once the information has been sent and verified, the user canstart the blending process (e.g., using the HMI and/or operator inputs116), and the controller 110 reports back to the HMI 108 informationregarding the blending process (e.g., an amount delivered, pumpingpressures, ingredient delivery rates, etc.). At the conclusion of theblending process the controller 110 updates the HMI 108 with finalamounts of each ingredient delivered, which will be stored in a database(e.g., the database 208 of FIG. 2 ) of the HMI 108. In some embodiments,the HMI 108 may report the information regarding the blending process,the final blending information, the recipe information, the deliveryprocess, other information, or combinations thereof to an outsidecomputing device (e.g., a server configured to collect information froma plurality of bulk explosive loading systems).

Once the controller 110 receives the recipe information from the HMI108, the controller can perform the blending and delivery of the mixtureindependent of the HMI 108. As a result, the controller 110 may becapable of performing the blending and delivery even if communicationwith the HMI 108 is interrupted or otherwise terminated.

The HMI 108 may be located anywhere on or around the bulk explosiveloading system 100. For example, in the illustrated embodiment, thelocation of the HMI 108 is within the truck cab 104. The HMI may belocated in a position that may enable the user to interface with thebulk explosive loading system 100 in relative comfort and safety, suchas the relative comfort and safety afforded by the truck cab 104. As aresult, the user may not be required to access external controls at ornear the electrically controllable components 112. In some embodiments,the HMI 108 may be external to the bulk explosive loading system 100.For example, an underground bulk explosive loading equipment may includean HMI near the rear of the equipment for accessibility. Although theHMI 108 enables the user to interface with the bulk explosive loadingsystem 100 within the truck cab 104, the operator inputs 116 may beconfigured to provide the user with additional and/or redundant(redundant with the user interface options provided by the HMI 108) userinterface options for interacting with the bulk explosive loading system100. By way of non-limiting example, the operator inputs 116 may includea manual override configured to enable the user to override blendingand/or delivery of a mixture.

The HMI 108 may be reconfigurable independent of the controller 110. Forexample, the communications interface between the HMI 108 and thecontroller 110 may allow the HMI 108 to be replaced or updated withoutthe need to update the controller 110. Additionally, the HMI 108 may bereconfigured based on the user. For example, the HMI 108 may limitaccess to certain parameters for some users.

FIG. 2 is a simplified block diagram of the bulk explosive loadingsystem 100 of FIG. 1 . As illustrated in FIG. 2 , the bulk explosiveloading system 100 includes a communication interface 202 configured toenable bi-directional communication between the HMI 108 and thecontroller 110. In some embodiments the communication interface 202includes a wired communication interface. By way of non-limitingexample, the communication interface 202 includes a two-wire interfacesuch as a Controller Area Network (CAN) bus. Also by way of non-limitingexample, the communication interface 202 may include a local areanetwork (LAN) cable such as an Ethernet cable. In some embodiments thecommunication interface 202 includes a wireless communication interfacesuch as a Bluetooth, Wi-Fi, ZigBee, or cellular communication interface.In some embodiments the communication interface 202 includes a securewireless communication interface to prevent outside tampering orinterference with dangerous mixing and delivery processes controlled bythe controller 110. Although in some embodiments the HMI 108 may becapable of communicating (e.g., wirelessly or through wired networks),in some such embodiments the controller 110 may only be configured forcommunication with the HMI 108 to guard safety of mixing and deliveringexplosives. The communication interface 202 allows for real-timecommunication between the HMI 108 and the controller 110 whilepreventing external systems and devices from accessing the controller110.

The HMI 108 includes one or more processors 206 operably coupled to oneor more data storage devices 204, an electronic display 214, and one ormore input devices 212. For simplicity the one or more processors 206,the one or more data storage devices 204, and the one or more inputdevices 212 are sometimes referred to herein as “processors” 206,“storage” 204, and “input devices” 212, respectively. By way ofnon-limiting example, the HMI 108 may include an industrial PersonalComputer (PC) running an operating system (e.g., Microsoft Windows,etc.). The storage 204 includes a database 208 and a softwareapplication 210 stored thereon. The software application 210 comprisescomputer-readable instructions (e.g., the computer-readable instructions606 of FIG. 6 ) configured to instruct the processors 206 to performoperations of the HMI 108. For example, the computer-readableinstructions are configured to instruct the one or more processors todisplay a graphical user interface (GUI) (e.g., the GUI 402 of FIG. 4 )on the electronic display 214.

The GUI may be configured to prompt a user to provide login credentialsfor secure access. For example, the GUI may present a login screen,based on the credentials entered by the user the one or more processors206 may determine a security level associated with the operator andreconfigure the HMI 108 or the GUI of the HMI 108 to allow or denyaccess to parameters (e.g., explosive mixture, amount of explosiveproduct to be used, delivery rate, etc.) based on the user's securitylevel. For example, in some embodiments multiple levels of userauthority are defined by the HMI 108. These may include operator,advanced operator, blast supervisor, blast engineer, and manufacturer.The HMI 108 may associate a minimum authority level with portions of thecomputer-readable instructions of the software application 210. If anoperator does not have the minimum authority level, the operator will beunable to perform functions associated with portions of thecomputer-readable instructions of the software application 210. Forexample, to view a formula screen that shows the explosive mixture to beused, an authority level equivalent to an advanced operator or blastsupervisor may be required. Further, to edit the explosive mixture, anauthority level of blast engineer may be required.

The HMI 108 may be reconfigured or updated (hardware or softwareapplication 210) without the need to reconfigure or update thecontroller 110. Additional features may be added to the HMI 108 withoutthe need to replace the controller 110. In some cases, reconfiguring thecontroller 110 may be difficult. Thus, adding features to the HMI 108without affecting the controller 110 is desirable.

The GUI is further configured to prompt the user of the HMI 108 toprovide, through the input devices 212, at least a portion of recipeinformation (e.g., the RECIPE/DELIVERY INFORMATION 316 of FIG. 3 ) forblending a mixture. The HMI 108 is configured to receive the user inputsthrough the input devices 212 (e.g., a mouse, a track pad, a keyboard, abutton array, a sensor of a touchscreen device built into the electronicdisplay 214, other input devices, or combinations thereof). By way ofnon-limiting example, the recipe information may include one or moreblending speeds (e.g., auger speeds), quantities of one or moreingredients to add to the mixture, one or more pump pressures, one ormore ingredient delivery rates to be used in blending the mixture (e.g.,auger speed, pump speed) or preparing a particular ingredient, a totalvolume of mixture, critical safety inputs, an instruction to startblending the mixture, other information, or combinations thereof. Therecipe information may also include mixture delivery information (e.g.,total volume of mixture to be delivered, delivery rate of mixture,etc.).

The computer-readable instructions are also configured to instruct theprocessors 206 to generate one or more signals to transmit the recipeinformation from the HMI 108 to the controller 110 through thecommunication interface 202. The recipe information is configured toindicate to the controller 110 how to blend and/or deliver the mixture.The computer-readable instructions are further configured to instructthe processors 206 to process blending information (e.g., the BLENDINGINFORMATION 322 of FIG. 3 ) received from the controller 110. Theblending information includes information regarding the blending of themixture. By way of non-limiting example, the blending information mayinclude data from the sensors 114 that was taken during blending of themixture, information indicating measured amounts of one or moreingredients delivered to the mixture, measured pumping pressures,measured ingredient delivery rates, other information, or combinationsthereof. The computer-readable instructions are also configured toinstruct the processors 206 to store the blending information in thedatabase 208.

In some embodiments the controller 110 may include an Electrical ControlUnit such as a Bosch Rexroth RC series controller. Similar to the HMI108, the controller 110 includes one or more processors 218 and one ormore data storage devices 216. For simplicity, the one or moreprocessors 218 and the one or more data storage devices 216 aresometimes referred to herein as “processors” 218 and “storage” 216,respectively. The storage 216 is configured to store computer-readableinstructions configured to instruct the processors 218 to performoperations of the controller 110.

The controller 110 is operably coupled to the sensors 114, the operatorinputs 116, and the electrically controllable components 112. Thecontroller 110 is configured to process the recipe information receivedfrom the HMI 108, and generate one or more control signals (e.g., thecontrol signals 318 of FIG. 3 ) to transmit to the electricallycontrollable components 112 through one or more control outputs. The oneor more control signals are based on the recipe information receivedfrom the HMI 108. In this way the controller 110 controls theelectrically controllable components 112 to blend the mixture. Theelectrically controllable components 112 may include one or morehydraulic valves, one or more process control valves (e.g., pneumatic orelectronic process valves), one or more auger motors, one or more pumps,or combinations thereof. In some embodiments, the controller 110 maycontrol hose retraction and/or a hopper. In some embodiments, thecontroller may track tank levels of ingredients used for the mixture. Ingenerating the control signals, the controller 110 may take intoconsideration the critical safety inputs received from the HMI 108through the communication interface 202.

During blending of the mixture, the controller 110 may monitor theblending processing, and provide the blending information to the HMI 108through the communication interface 202. To gather the blendinginformation the controller 110 may use the sensors 114 to monitor theblending processing. The controller 110 may be configured to receive oneor more sensor signals (e.g., the SENSOR SIGNALS 320 of FIG. 3 ) fromthe sensors 114. By way of non-limiting example, the sensors 114 mayinclude one or more pressure sensors, one or more temperature sensors,one or more pump speed sensors, one or more auger motor speed sensors,level sensors, flow meters, other sensors, or combinations thereof. Thecontroller 110 may be configured to generate one or more signalsincluding blending information (e.g., the BLENDING INFORMATION 322 ofFIG. 3 ) and transmit the blending information to the HMI 108. Once theblending processing is completed the controller 110 may be configured togenerate one or more signals including final blending information (e.g.,the FINAL BLENDING INFORMATION 324 of FIG. 3 ) to be transmitted to theHMI 108 through the communication interface 202. The final blendinginformation may be configured to indicate final amounts of theingredients that were delivered to the mixture during blendingprocessing.

The HMI 108 and the controller 110 may perform operations independent ofeach other. For example, once the controller 110 receives the recipeinformation from the HMI 108, the controller 110 can perform theblending and delivery of the mixture independent of the HMI 108. As aresult, the controller 110 may be capable of performing the blending anddelivery even if communication with the HMI 108 is interrupted orotherwise terminated.

Additionally, the independence between the HMI 108 and the controller110 may allow alterations of the HMI 108. For example, the HMI 108 maybe replaced, the software application 210 may be updated, or the HMI 108may be reconfigured for a user without the need to alter the controller110. For example, the HMI 108 may provide a custom interface based onthe operator's credentials. The custom interface may provide access toinputs or functions of the software application 210 associated with aminimum authority level that is equivalent to or less than the securitylevel associated with the operator credentials.

In some embodiments the controller 110 may be located inside of aninput/output (IO) junction box.

In some embodiments, the bulk explosive loading system 100, furthercomprises a global positioning system (GPS). The HMI 108 or thecontroller 110 may track an amount of the explosive mixture used to filla borehole and associate a coordinate from the GPS with the amount. TheHMI 108 may compile data collected during use to generate a report andexport the report. For example, the HMI may provide a delivery log ofthe amount of explosive mixture at each blasthole coordinate. This mayallow an operator to determine blastholes where excess explosive mixturewas placed, or blastholes where insufficient explosive mixture wasplaced. The HMI may also provide an overall delivery report thatprovides a total amount of explosive mixture delivered across multipleblastholes. Additionally, the delivery report may indicate how much ofeach product used in the explosive mixture was used. These reports maybe used to determine billing based on amount of product used.

FIG. 3 is a simplified signal flow diagram of the bulk explosive loadingsystem 100 of FIG. 1 . As previously discussed, the bulk explosiveloading system 100 comprises an HMI 108, a controller 110, electricallycontrollable components 112, and sensors 114. In operation, the HMI 108receives user inputs for at least a portion of RECIPE/DELIVERYINFORMATION 316 of a mixture to be blended. The HMI 108 is configured totransmit the RECIPE/DELIVERY INFORMATION 316 to the controller 110, andthe controller 110 is configured to verify 304 the RECIPE/DELIVERYINFORMATION 316 received from the HMI 108. In some embodiments, thecontroller 110 is configured to transmit a ready signal to the HMI 108to indicate that the controller is ready and able to begin blending themixture.

A user input to start the blending process is received 306. For example,the user input may be received 306 through the user interface of the HMI108, through the operator inputs 116, or both. If received by the HMI108, the HMI 108 transmits the input to start to the controller 110. Insome embodiments the user input to start the blending process may be areal-time or quasi real-time instruction to start the blending processesresponsive to the user input. In some embodiments the user input maydefine a time for the start of the blending process, or a delay may beintroduced from reception of the user input before the blending processbegins. Responsive to the user input to start the blending process, thecontroller 110 may start 308 the blending process. As previouslydiscussed, the blending and delivery process may continue withoutfurther communication with the HMI 108.

During the blending processing the controller 110 may transmit controlsignals 318 to the electrically controllable components 112 to controlthe blending process. Also during the blending processing, thecontroller 110 may receive SENSOR SIGNALS 320 from the sensors 114.During the blending process, the controller 110 may further generate andtransmit, to the HMI 108, one or more signals including BLENDINGINFORMATION 322. The HMI 108 receives and stores 310 the blendinginformation in the database 208 (FIG. 2 ). The transmission of thecontrol SENSOR SIGNALS 320, the SENSOR SIGNALS 320, and the BLENDINGINFORMATION 322 may occur repeatedly during the blending process, mayoccur simultaneously or non-simultaneously, and may occur in variousdifferent chronological orders.

When the blending processing is complete, the controller 110 stops 312the blending processing. The controller 110 generates one or moresignals including FINAL BLENDING INFORMATION 324, and transmits theFINAL BLENDING INFORMATION 324 to the HMI 108. The HMI 108 stores 314the FINAL BLENDING INFORMATION 324 in the database 208 (FIG. 2 ).

FIG. 4 is a simplified view of an example of a graphical user interface(GUI) 402 displayed by the electronic display 214 of the HMI 108 of thebulk explosive loading system 100 of FIG. 1 , according to someembodiments. The GUI 402 includes one or more ingredient quantity/ratioinputs 404, one or more ingredient delivery rate inputs 406, one or moreingredient blending speed inputs 408, one or more pump pressure inputs410, a total volume of mixture input 414, a delivery rate of mixtureinput 416, and a start blending option 412. Each of inputs 404, 406, 408410, 414, 416 may be configured to enable a user to manually inputquantities, select one or more quantities from a list (e.g., a dropdownlist), or otherwise indicate desired quantities for input.

The ingredient quantity/ratio inputs 404 may be configured to enable theuser to set or adjust the quantity or ratio (i.e., the ratio of a volumeor mass of the ingredient to the volume or mass of the final mixture) ofthe ingredients in a recipe. By way of non-limiting example, aningredient A may include an emulsion explosive. Emulsion explosives arecommonly used in the mining, quarrying, and excavation industries.Emulsion agents are generally transported to a job site as an emulsionthat is too dense to completely detonate. In general, the emulsion needsto be “sensitized” in order for the emulsion to detonate successfully.Sensitizing is often accomplished by introducing small voids into theemulsion (e.g., using a chemical gassing agent, as discussed below).These voids act as hot spots for propagating detonation. These voids maybe introduced by blowing a gas into the emulsion and thereby forming gasbubbles, adding microspheres, other porous media, and/or injectingchemical gassing agents to react in the emulsion and thereby form gas.In some embodiments the ingredient quantity/ratio input 404 foringredient A may enable the user to select between various densities ofthe emulsion explosive (e.g., densities of between about 0.6 to 1.4 insteps of 0.1) and in different quantities or ratios of the finalmixture. For example, a user may select a density of 1.1 and a ratio of60 percent of the final mixture, with the balance being ANFO, which insome embodiments may be ingredient B.

In some embodiments a chemical gassing agent may be used to react withthe emulsion explosive (e.g., ingredient A). By way of non-limitingexample, a chemical gassing agent may include peroxides such as hydrogenperoxide, inorganic nitrite salts such as sodium nitrite, nitrosaminessuch as N,N′-dinitrosopentamethylenetetramine, alkali metal borohydridessuch as sodium borohydride and bases such as carbonates including sodiumcarbonate. Any chemical gassing agent known in the art and compatiblewith the emulsion explosive may be used. The chemical gassing agent maybe dissolved in an aqueous solution.

The chemical gassing agent may be used to change the density of theemulsion explosive (e.g., ingredient A) to a desired density (e.g., tothe density selected or otherwise input into the GUI 402 using theingredient quantity/ratio input 404 for ingredient A). By way ofnon-limiting example, the software application 210 (FIG. 2 ) of the HMI108 (FIGS. 1-3 ) may be configured determine how much of the chemicalgassing agent to add to the emulsion explosive to achieve the desireddensity. Also by way of non-limiting example, the controller 110 (FIGS.1-3 ) may be configured to determine how much of the chemical gassingagent to add to the emulsion explosive to achieve the desired density.As a further non-limiting example, the user may determine how much ofthe chemical gassing agent to add to the emulsion explosive and providethe determined amount to the HMI 108 through the GUI 402 or to thecontroller 110 through the operator inputs 116 (FIGS. 1-2 ). Inembodiments where the HMI 108 or the controller 110 determines theamount of the chemical gassing agent to add, the HMI 108 or thecontroller 110 may be configured to use algorithms (e.g., equations) orlookup tables to determine the amount of the chemical gassing agent toadd. These algorithms and lookup tables may take into considerationtemperature of the emulsion matrix, which impacts the density of thefinal emulsion explosive. As a result, in embodiments where the HMI 108or the controller 110 determines the amount of the chemical gassingagent to add, inputs from the sensors 114 (FIGS. 1-3 ) (e.g.,temperature sensors) may be used in the determination of how much of thechemical gassing agent to add. In embodiments where the HMI 108 makesthe determination, the temperature sensor information from the sensors114 may be transmitted from by the controller 110 to the HMI 108 throughthe communication interface 202 (FIG. 2 ).

In some embodiments, a pH control agent such as an acid may be added tothe emulsion explosive. Examples of acids include, but are not limitedto, organic acids such as citric acid, acetic acid, and tartaric acid.Any pH control agent known in the art and compatible with the chemicalgassing agent may be used. The pH agent may be dissolved in an aqueoussolution. Similarly as discussed above with reference to the chemicalgassing agent, the HMI 108, the user, or the controller 110 maydetermine an amount of the PH control agent to add to the emulsion.Sensor inputs may be used in conjunction with algorithms (e.g.,equations) and/or lookup tables to determine the amount of the PHcontrol agent to add to the emulsion.

As previously mentioned, in some embodiments ingredient B may includeANFO, which includes a mixture of blasting agents ammonium nitrate(NH₄NO₃) (AN) and fuel oil (e.g., number 2 fuel oil (FO)). For example,the ammonium nitrate may include porous prilled ammonium nitrate. Theingredient quantity/ratio input 404 for ingredient B may enable the userto select for ingredient B (e.g., ANFO) between various quantities orratios of the final mixture.

In some embodiments, an ingredient C may also be used. In suchembodiments, the ingredient quantity/ratio input 404 for ingredient Cmay enable the user to select for ingredient C between variousquantities or ratios of the final mixture.

The ingredient delivery rate inputs 406 may be optional inputs (in otherembodiments the HMI 108 or the controller 110 may automatically selectdelivery rates) that may be included in some embodiments of the GUI 402.In some such embodiments the ingredient delivery rate inputs 406 areconfigured to enable the user to set or adjust the rate of delivery ofthe ingredients. The ingredient blending speed inputs may also beoptional inputs that may be included in some embodiments of the GUI 402.The ingredient blending speed inputs 408 are configured to enable theuser to set or adjust the speed with which the ingredients are blended(e.g., the speed of a mixing auger). The pump pressure inputs may alsobe optional inputs that may be included in some embodiments of the GUI402. The pump pressure inputs 410 are configured to enable the user toset or adjust pressures of pumps to be used in the blending and/ordelivery processes. The start blending option 412 (also an optionalinput) is configured to enable the user to start the blending processfrom inside of the truck cab 104.

The total volume of blended mixture option 414 is configured to enablethe user to set or select a total volume to be mixed and/or delivered.The delivery rate of mixture option 416 is configured to enable the userto set or select a rate of delivery or deployment of the final mixtureto the blast site.

Using the ingredient quantity/ratio inputs 404, the total volume ofmixture input 414, and the delivery rate of mixture input 416, the HMI108 (FIGS. 1-3 ) may create recipes to be transmitted to the controller110 (FIG. 1 ). In some embodiments, the HMI 108 may be configured tostore these recipes for later user. In some embodiments, the GUI 402 maybe configured to present previously used recipes for later inspectionand adjustment using the ingredient quantity/ratio inputs 404, the totalvolume of mixture input 414, and the delivery rate of mixture input 416.In some embodiments, the HMI 108 may be configured to downloadpre-defined recipes from one or more servers (not shown) (e.g., throughthe internet). By way of non-limiting example, an ingredientmanufacturer or mining/drilling company may provide various recipesonline for use in the field. Also by way of non-limiting example,recipes may be shared from user to user via one or more social mediaplatforms. These pre-defined recipes may be viewed and modified usingthe GUI 402.

FIG. 5 is a simplified flowchart illustrating a method 500 oftransforming a computer 604 (FIG. 6 ) into the HMI 108 of the bulkexplosive loading system 100 of FIG. 1 , according to some embodiments.

FIG. 6 is a simplified block diagram of a system 600 illustrating themethod 500 of FIG. 5 . Referring to FIGS. 5 and 6 together, the method500 comprises storing 502, on a data storage device 602,computer-readable instructions 606 of a software application (e.g., thesoftware application 210 of FIG. 2 ) to be executed by one or moreprocessors 206 of the computer 604. In some embodiments the data storagedevice 602 is a data storage device of a software application deliveryserver (e.g., a server of a software application store such as iTunes orGoogle Play). In some embodiments the data storage device 602 comprisesa distributable computer-readable medium such as a disc (e.g., a compactdisc (CD), a digital versatile disc (DVD), a Blu-ray, a Flash drive,other distributable medium, or combinations thereof).

The method 500 also includes transferring 504 the computer-readableinstructions 606 from the data storage device 602 to a non-transitorycomputer-readable storage medium (e.g., the storage 204) of the computer604. In some embodiments transferring 504 the computer-readableinstructions 606 from the data storage device 602 to thecomputer-readable non-transitory computer-readable storage medium of thecomputer 604 includes transmitting the computer-readable instructions606 from a software application delivery server to the computer 604through an Internet Protocol (IP) network. In some embodimentstransferring 504 the computer-readable instructions 606 from the datastorage device 602 to the computer-readable non-transitorycomputer-readable storage medium of the computer 604 includes shippingthe data storage device 602 to enable physical connection of the datastorage device to the computer 604.

The computer-readable instructions 606 are configured to transform thecomputer 604 into the HMI 108. Accordingly, the computer-readableinstructions 606 are configured to instruct the processors 206 toperform the functions of the HMI 108, as discussed above. For example,the computer-readable instructions 606 are configured to instruct theprocessors 206 to display a GUI (e.g., the GUI 402 of FIG. 4 ). The GUIis configured to prompt a user of the HMI 108 to provide, through one ormore user input devices (e.g., input devices 212 of FIG. 2 ) at least aportion of recipe information for blending a mixture. The recipeinformation can include one or more blending speeds, quantities/ratiosof one or more ingredients to add to the mixture, a total volume ofmixture, and a delivery rate of the mixture.

The computer-readable instructions 606 are also configured to instructthe processors 206 to transmit the recipe information from the HMI 108through a communication interface (e.g., the communication interface 202of FIG. 2 ) to the controller 110 (FIGS. 1-3 ). The recipe informationis configured to indicate to the controller 110 how to blend themixture. In some embodiments, the computer-readable instructions 606 arealso configured to instruct the processors 206 signal to the controller110 to start blending and/or delivering the mixture according to therecipe information. In some embodiments the computer-readableinstructions 606 are configured to instruct the processors 206 totransmit, to the controller 110, critical safety constraints forblending the mixture.

The computer-readable instructions 606 are further configured toinstruct the processors 206 to process blending information receivedfrom the controller 110 through the communication interface. Theblending information includes information regarding the blending of themixture. In some embodiments the blending information includes data fromone or more sensors (e.g., the sensors 114 of FIGS. 1-3 ). By way ofnon-limiting example the one or more sensors may include one or morepressure sensors, one or more temperature sensors, one or more pumpspeed sensors, one or more auger motor speed sensors, other sensors, orcombinations thereof. The computer-readable instructions 606 areconfigured to instruct the processors 206 to store the blendinginformation in one or more databases (e.g., the database 208 of FIG. 2 )stored in storage 204 of the computer 604. In some embodiments thecomputer-readable instructions 606 are configured to instruct theprocessors 206 to process and store final blending information receivedfrom the controller 110. The final blending information may indicatefinal measured amounts of one or more ingredients delivered to themixture.

It should be understood by those having skill in the art that manychanges may be made to the details of the above-described embodimentswithout departing from the underlying principles of the disclosure. Thescope of the present disclosure should, therefore, be determined only bythe following claims.

1-20. (canceled)
 21. A mobile bulk explosive loading system, comprising:electrically controllable components configured to mix and deliver anexplosive mixture to a blast site; a controller operably coupled to theelectrically controllable components, the controller configured tocontrol the electrically controllable components to mix and deliver theexplosive mixture according to recipe information and deliveryinformation; a human-machine interface (HMI) device comprising: aprocessor; and a data storage device to store computer-readableinstructions configured to instruct the processor to: present, on anelectronic display of the HMI device, a graphical user interface (GUI),the GUI including user inputs for parameters of an explosive delivery;transform the parameters of the user inputs to instructions for thecontroller to follow when blending and delivering the explosive; store,on the data storage device, the instructions for the controller as therecipe information and the delivery information; and a communicationinterface configured to enable bi-directional communication between theHMI device and the controller, the communication interface configured todeliver the recipe information and the delivery information generated bythe HMI device to the controller to enable the controller to control theelectrically controllable components according to the recipe informationand the delivery information.
 22. The mobile bulk explosive loadingsystem of claim 21, wherein to transform the parameters of the userinputs, the HMI device determines one or more of a delivery rate, anamount of a PH control agent to add to an emulsion explosive, and anamount of a chemical gassing agent to add to the emulsion explosive toachieve a desired density.
 23. The mobile bulk explosive loading systemof claim 21, further comprising one or more sensors operably coupled tothe controller, the one or more sensors including at least a temperaturesensor configured to measure a temperature of an emulsion matrix,wherein the controller is configured to transmit temperature informationreceived from the temperature sensor to the HMI device through thecommunication interface to enable the HMI device to determine properamounts of one or more gassing agents to add to the emulsion explosiveto achieve a desired density of the emulsion explosive.
 24. The mobilebulk explosive loading system of claim 21, wherein the softwareapplication is further configured to instruct the HMI device to: receiveoperator credentials; determine a security level associated with theoperator credentials; and reconfigure the HMI device to provide accessto inputs associated with a minimum authority level that is equivalentto or less than the security level associated with the operatorcredentials.
 25. The mobile bulk explosive loading system of claim 21,further comprising a global positioning system (GPS), wherein the HMIdevice is further to: track an amount of the explosive mixture used tofill a borehole; associate a coordinate from the GPS with the amount;and provide a delivery log of the amount of explosive mixture at thecoordinate.
 26. The mobile bulk explosive loading system of claim 21,wherein the HMI device uses a lookup table to transform the parametersof the user inputs to instructions for the controller.
 27. The mobilebulk explosive loading system of claim 21, wherein the controllertransits blending information via the communication interface to the HMIdevice, the blending information comprising pumping pressures,ingredient delivery rates, or combinations thereof, and wherein the HMIdevice compiles the blending information, generates a report based onthe blending information, and exports the report.
 28. A method for bulkexplosive loading, the method comprising: presenting, on an electronicdisplay of a human-machine interface (HMI) device a graphical userinterface (GUI), the GUI including user inputs for parameters of anexplosive delivery; transforming, at the HMI device, the parameters ofthe user inputs to instructions for a controller to follow when blendingand delivering the explosive; storing, on a data storage device of theHMI device, the instructions for the controller as recipe informationand delivery information; sending, via a communication interface, therecipe information and the delivery information from the HMI device tothe controller; and controlling, via the controller, electricallycontrollable components to mix and deliver the explosive mixtureaccording to recipe information and delivery information generated bythe HMI device.
 29. The method of claim 28, wherein to transforming theparameters of the user inputs comprises determining one or more of adelivery rate, an amount of a PH control agent to add to an emulsionexplosive, and an amount of a chemical gassing agent to add to theemulsion explosive to achieve a desired density.
 30. The method of claim28, further comprising receiving measurements from one or more sensorsoperably coupled to the controller, the one or more sensors including atleast a temperature sensor configured to measure a temperature of anemulsion matrix, and transmitting temperature information received fromthe temperature sensor to the HMI device through the communicationinterface to enable the HMI device to determine proper amounts of one ormore gassing agents to add to the emulsion explosive to achieve adesired density of the emulsion explosive.
 31. The method of claim 28,further comprising receiving operator credentials; determining asecurity level associated with the operator credentials; andreconfiguring the HMI device to provide access to inputs associated witha minimum authority level that is equivalent to or less than thesecurity level associated with the operator credentials.
 32. The methodof claim 28, further comprising tracking an amount of the explosivemixture used to fill a borehole; associating a coordinate from a globalpositioning system (GPS) with the amount; and providing a delivery logof the amount of explosive mixture at the coordinate.
 33. The method ofclaim 28, wherein the controller mixes and delivers the explosivemixture independent of the HMI device.
 34. The method of claim 28,transiting, from the controller, blending information via thecommunication interface to the HMI device, the blending informationcomprising pumping pressures, ingredient delivery rates, or combinationsthereof, and compiling, via the HMI device, the blending information,generates a report based on the blending information, and exports thereport.
 35. A mobile bulk explosive loading system, comprising:electrically controllable components configured to mix and deliver anexplosive mixture to a blast site; a controller operably coupled to theelectrically controllable components, the controller configured tocontrol the electrically controllable components to mix and deliver theexplosive mixture according to recipe information and deliveryinformation; a human-machine interface (HMI) device comprising: aprocessor; and a data storage device to store computer-readableinstructions configured to instruct the processor to: present, on anelectronic display of the HMI device, a graphical user interface (GUI),the GUI including user inputs for parameters of an explosive delivery;transform the parameters of the user inputs to instructions for thecontroller to use when blending and delivering the explosive; store, onthe data storage device, the instructions for the controller as therecipe information and the delivery information; and send the recipeinformation and the delivery information to the controller to enable thecontroller to control the electrically controllable components accordingto the recipe information and the delivery information.
 36. The mobilebulk explosive loading system of claim 35, wherein to transform theparameters of the user inputs, the HMI device determines one or more ofa delivery rate, an amount of a PH control agent to add to an emulsionexplosive, and an amount of a chemical gassing agent to add to theemulsion explosive to achieve a desired density.
 37. The mobile bulkexplosive loading system of claim 35, further comprising one or moresensors operably coupled to the controller, the one or more sensorsincluding at least a temperature sensor configured to measure atemperature of an emulsion matrix, wherein the controller is configuredto transmit temperature information received from the temperature sensorto the HMI device to enable the HMI device to determine proper amountsof one or more gassing agents to add to the emulsion explosive toachieve a desired density of the emulsion explosive.
 38. The mobile bulkexplosive loading system of claim 35, wherein the software applicationis further configured to instruct the HMI device to: receive operatorcredentials; determine a security level associated with the operatorcredentials; and reconfigure the HMI device to provide access to inputsassociated with a minimum authority level that is equivalent to or lessthan the security level associated with the operator credentials. 39.The mobile bulk explosive loading system of claim 35, further comprisinga global positioning system (GPS), wherein the HMI device is further to:track an amount of the explosive mixture used to fill a borehole;associate a coordinate from the GPS with the amount; and provide adelivery log of the amount of explosive mixture at the coordinate. 40.The mobile bulk explosive loading system of claim 35, wherein thecontroller transits blending information to the HMI device, the blendinginformation comprising pumping pressures, ingredient delivery rates, orcombinations thereof, and wherein the HMI device compiles the blendinginformation, generates a report based on the blending information, andexports the report.